Electronic connector assembly for power transmitting devices

ABSTRACT

A power transmitting device, such as a differential, having a housing, input and output shafts, which are rotatably disposed in the housing, a gear set, one or more actuators and/or one or more sensors disposed within the housing, and a connector having a fitting, a seal member and a locking member. The gear set is operable for transmitting rotary power between the input and output shafts. The fitting has a body that extends through a hole formed in the housing. The body includes a plurality of terminals that are electrically coupled to the at least one electrical components. The seal member is disposed between the fitting and the housing to form a seal therebetween. The locking member engages the body and the housing to retain the fitting to the housing. The fitting facilitates electrical connection of the electrical components within the housing with a wire harness that is external to the housing.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.10/958,130, filed. Oct. 4, 2004 which claims the benefit of U.S.Provisional Application No. 60/508,923, filed on Oct. 6, 2003. Thedisclosure of the above application is incorporated herein by reference.

FIELD OF THE INVENTION

The present invention generally relates to automotive drivelines andmore particularly to a bulkhead connector that facilitates theelectronic coupling of sensors and actuators within an enclosed housingto a wire harness located exterior to the housing.

SUMMARY OF THE INVENTION

In one form, the present invention provides a power transmitting device,such as a differential, having a housing, input and output shafts, whichare rotatably disposed in the housing, a gear set, one or more actuatorsand/or one or more sensors disposed within the housing, and a connectorhaving a fitting, a seal member and a locking member. The gear set isoperable for transmitting rotary power between the input and outputshafts. The fitting has a body that extends through a hole formed in thehousing. The body includes a plurality of terminals that areelectrically coupled to the at least one electrical components. The sealmember is disposed between the fitting and the housing to form a sealtherebetween. The locking member engages the body and the housing toretain the fitting to the housing. The fitting facilitates electricalconnection of the electrical components within the housing with a wireharness that is external to the housing. The fitting and wire harnessmay also be keyed to one another to ensure that they may only beassembled in one manner and to prevent the wire harness and fitting fromrotating relative to one another.

Further areas of applicability of the present invention will becomeapparent from the detailed description provided hereinafter. It shouldbe understood that the detailed description and specific examples, whileindicating the preferred embodiment of the invention, are intended forpurposes of illustration only and are not intended to limit the scope ofthe invention.

BRIEF DESCRIPTION OF THE DRAWINGS

Additional advantages and features of the present invention will becomeapparent from the subsequent description and the appended claims, takenin conjunction with the accompanying drawings, wherein:

FIG. 1 is a schematic illustration of an exemplary vehicle having anelectronic locking differential constructed in accordance with theteachings of the present invention;

FIG. 2 is a top partially cut-away view of a portion of the vehicle ofFIG. 1 illustrating the rear axle and the propshaft in greater detail;

FIG. 3A is a sectional view illustrating the rear axle in greaterdetail;

FIG. 3B is a sectional view of a portion of the differential;

FIG. 4 is an exploded perspective view of a portion of the rear axleillustrating a portion of the electronic locking differential and thebulkhead connector;

FIG. 5 is a sectional view of a portion of the rear axle takenlongitudinally through the bulkhead connector;

FIG. 6 is a sectional view taken along the line 6-6 of FIG. 5;

FIG. 6A is a sectional view taken along the line 6A-6A of FIG. 5;

FIG. 7 is a sectional view similar to that of FIG. 5 but illustratingthe configuration of another bulkhead connector constructed inaccordance with the teachings of the present invention;

FIG. 8 is a sectional view similar to that of FIG. 5 but illustratingthe configuration of yet another bulkhead connector constructed inaccordance with the teachings of the present invention;

FIG. 9 is an exploded perspective view similar to that of FIG. 4, butillustrating an alternate locking member; and

FIG. 10 is a partial sectional view of the bulkhead connector of FIG. 9illustrating the bulkhead connector in the installed condition.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

With reference to FIG. 1 of the drawings, an exemplary vehicle having arear axle that is constructed in accordance with the teachings of thepresent invention is generally indicated by reference numeral 10. Thevehicle 10 includes a driveline 12 drivable via a connection to a powertrain 14. The power train 14 includes an engine 16 and a transmission18. The driveline 12 includes a propshaft assembly 20, a rear axle 22and a plurality of wheels 24. The engine 16 is illustrated in theexample provided to be mounted in an in-line or longitudinal orientationalong the axis of the vehicle 10 and its output is selectively coupledvia a conventional clutch (not shown) to the input of the transmission18 to transmit rotary power (i.e., drive torque) therebetween. The inputof the transmission 18 is commonly aligned with the output of the engine16 for rotation about a rotary axis. The transmission 18 also includesan output 18 a and a gear reduction unit 18 b. The gear reduction unit18 b is operable for coupling the transmission input (not shown) to thetransmission output 18 a at a predetermined gear or speed reductionratio. The propshaft assembly 20 is coupled for rotation with the output18 a of the transmission 18. Drive torque is transmitted through thepropshaft assembly 20 to the rear axle 22 where it is selectivelyapportioned in a predetermined manner to the left and right rear wheels24 a and 24 b, respectively.

With additional reference to FIGS. 2 through 3B, the rear axle 22 isshown to include a differential assembly 30, a left axle shaft assembly32 and a right axle shaft assembly 34. The differential assembly 30 isan electronic locking differential and for example, may be of the typethat is well known in the art and commercially available from variousdifferent manufacturers, including American Axle & Manufacturing Companyof Detroit, Mich. Two particularly well suited electronic lockingdifferentials are manufactured and marketed by American Axle &Manufacturing Company as the TracRite™ EL and the TracRite™ ECV.

The differential assembly 30 includes a housing 40, a differential unit42, an input shaft assembly 44, and an electronic actuation system 45.The housing 40 supports the differential unit 42 for rotation about afirst axis 46 and further supports the input shaft assembly 44 forrotation about a second axis 48 that is perpendicular to the first axis46. The housing 40 may be initially formed in a suitable casting processand thereafter machined as required. The housing 40 includes a wallmember 50 that defines a central cavity 52 having a left axle aperture54, a right axle aperture 56, an input shaft aperture 58. The wallmember 50 may further define a boss 60 having a through-hole 64 formedtherethrough.

The differential unit 42 is disposed within the central cavity 52 of thehousing 40 and includes a case 70, a ring gear 72 that is fixed forrotation with the case 70, and a gearset 74 that is disposed within thecase 70. The gearset 74 includes first and second side gears 82 and 86and a plurality of differential pinions 88, which are rotatablysupported by brake shoes 90 in a conventional and well known manner. Thecase 70 includes a pair of trunnions 92 and 96 and defines a gear cavity98. A pair of bearing assemblies 102 and 106 are shown to support thetrunnions 92 and 96, respectively, for rotation about the first axis 46.The left and right axle assemblies 32 and 34 extend through the left andright axle apertures 54 and 56, respectively, where they are coupled forrotation about the first axis 46 with the first and second side gears 82and 86, respectively. The case 70 is operable for supporting theplurality of differential pinions 88 for rotation within the gear cavity98 about one or more axes that are perpendicular to the first axis 46.The first and second side gears 82 and 86 each include a plurality ofteeth 108 which meshingly engage teeth 110 that are formed on thedifferential pinions 88.

The input shaft assembly 44 extends through the input shaft aperture 58where it is supported in the housing 40 for rotation about the secondaxis 48. The input shaft assembly 44 includes an input shaft 120, apinion gear 122 having a plurality of pinion teeth 124 that meshinglyengage the teeth 126 that are formed on the ring gear 72, and a pair ofbearing assemblies 128 and 130 which cooperate with the housing 40 torotatably support the input shaft 120. The input shaft assembly 44 iscoupled for rotation with the propshaft assembly 20 and is operable fortransmitting drive torque to the differential unit 42. Morespecifically, drive torque received the input shaft 120 is transmittedby the pinion teeth 124 to the teeth 126 of the ring gear 72 such thatdrive torque is distributed through the differential pinions 88 to thefirst and second side gears 82 and 86.

The left and right axle shaft assemblies 32 and 34 include an axle tube150 that is fixed to the associated axle aperture 54 and 56,respectively, and an axle half-shaft 152 that is supported for rotationin the axle tube 150 about the first axis 46. Each of the axlehalf-shafts 152 includes an externally splined portion 154 thatmeshingly engages a mating internally splined portion (not specificallyshown) that is formed into the first and second side gears 82 and 86,respectively.

In the particular embodiment illustrated, the electronic actuationsystem 45 includes a coil 200, an armature 204, a sensor 208 and abulkhead connector 212. The coil 200 is mounted in a fixed positionrelative to the housing 40 and is operable in a first or unenergizedcondition in which the coil 200 does not generate a magnetic field thatis capable of altering or changing the position of the armature 204, anda second or energized condition in which the coil 200 generates amagnetic field that is cable of altering or changing the position of thearmature 204. The armature 204 is slidably mounted on the case 70 so asto be positionable in a first position, which permits relative rotationbetween the case 70 and the first side gear 82, and a second position,which inhibits relative rotation between the case 70 and the first sidegear 82. As those skilled in the art will appreciate from thisdisclosure, the armature 204 may directly lock or unlock the case 70 andthe first side gear 82 to one another, or may indirectly cause thelocking and unlocking of the case 70 and the first side gear 82 to oneanother. In configurations where the armature 204 is employed toindirectly lock and unlock the case 70 and the first side gear 82 to oneanother, devices such as a ball ramp mechanism (not shown) may beemployed to translate another element, such as one or more pins (notshown), into engagement with the first side gear 82 (e.g., engagement ofthe pins to corresponding holes formed in the first side gear 82) tothereby inhibit relative rotation between the case 70 and the first sidegear 82. Such arrangements whereby the armature 204 is employed toindirectly lock and unlock the case to a side gear are well known in theart and as such, need not be described in further detail herein.

With reference to FIG. 4, the bulkhead connector 212 is electricallyinterconnected to the coil 200 and the sensor 208 and facilitates theelectrical interconnection of the coil 200 and the sensor 208 with awire harness 250 that is external to the differential assembly 30. Asthose of ordinary skill in the art will appreciate from this disclosure,the wire harness 250 electrically couples the coil 200 and the sensor208 to an associated controller 254 to permit the controller 254 toselectively control the coil 200 and to receive the sensor signalproduced by the sensor 208. In the example provided, the bulkheadconnector 212 includes a fitting 300, at least one seal 304 and alocking member 308.

The fitting 300 may include a body portion 312 and a flange 316. Thebody portion 312 is sized so as to be received through a through-hole 64that is formed in the housing 40 of the differential assembly 30. Thethrough-hole 64 is illustrated to be formed through a dedicated boss 60,but may alternatively be formed through any portion of the wall member50 having sufficient thickness to ensure both sealing and engagement, aswill be discussed in greater detail, below.

In the particular example provided, the body portion 312 is generallycylindrically shaped, having a connector end 320 with a plurality ofterminals 324 that are configured to be engaged with the terminals 328in a mating connector 332 on the wire harness 250. The connector end 320and mating connector 332 may be keyed to one another in a conventionaland well known manner to guide the terminals 324 and 328 into engagementwith one another and/or to only permit the connector end 320 and matingconnector 332 to be coupled to one another in a specific orientation, orthe connector end 320 and mating connector 332 may be keyed about thebody portion 312.

With renewed reference to FIG. 4, the body portion 312 of the fitting300 also includes a retainer groove 340 and an optional seal groove 348.The retainer groove 340 may extend around the entire perimeter of thebody portion 312 as is shown in FIG. 6, or may be configured to inhibitrotation of the body portion 312 relative to the housing 40 if rotationof the fitting 300 subsequent to the installation of the bulkheadconnector 212 to the differential assembly 30 is disadvantageous. As oneof ordinary skill in the art can appreciate, rotation of the bodyportion 312 can be inhibited in numerous different ways, includingforming the retainer groove 340 about only a portion of the perimeter ofthe body portion 312 as shown in FIG. 6A, by forming the retainer groove340 in two or more discrete sections (e.g., on opposite sides of thebody portion 312) or by forming the body portion 312 in such a way thatit matingly engages the base portion 364 of the locking member 308 whenthe legs 360 of the locking member 308 are disposed in the retainergroove 340. It can be appreciated, too, that the retainer groove 340need not be of a uniform depth about any portion of the body portion 312and as such, the retainer groove 340 can be formed in whole or in partby any means, including flats.

The seal groove 348 is formed about the perimeter of the body portion312 on a side of the retainer groove 340 opposite the connector end 320and has a shape that is complementary to that of the seal 304. In theparticular example provided, the seal 304 is a conventional 0-ring andas such, the seal groove 348 has a semi-circular shape. As those ofordinary skill in the art will appreciate from this disclosure,employment of the seal groove 348 operably retains the seal 304 in apredetermined location relative to the retainer groove 340 along thelength of the body portion 312.

The flange 316 is relatively larger in diameter than the body portion312 and as such, prevents the fitting from being pushed completelythrough the housing 40 of the differential assembly 30 during theinstallation of the bulkhead connector 212. The flange 316 tends toshield the through-hole 64 from lubricant that is splashed about theinterior of the housing 40 and also cooperates with the housing 40 toform a labyrinth 356 (FIG. 5) that renders the infiltration of thelubricant into the through-hole 64 relatively difficult.

As noted above, the locking member 308 is employed to fixedly butremovably retain the fitting 300 to the housing 40. In the particularembodiment illustrated, the locking member 308 is a generally U-shapedstructure, having a pair of legs 360 that are spaced apart from oneanother by a base portion 364. With additional reference to FIG. 6, thelegs 360 are configured to slidably engage the retainer groove 340 inthe body portion 312 of the fitting 300. The base portion 364 may alsoengage a flat on the retainer groove 340 as is shown in FIG. 6A. Also,with reference to FIGS. 6 and 6A, the base portion 364 includes athrough-hole 368 that permits a threaded fastener 372 to be receivedthrerethrough; the threaded fastener 372 is threadably engaged to thehousing 40 to thereby fixedly but removably couple the locking member308 to the housing 40. Engagement of the locking member 308 to theretainer groove 340 in conjunction with the coupling of the lockingmember 308 to the housing 40 effectively inhibits movement of thefitting 300 within the through-hole 64. Thereafter, the connector end320 may be electrically coupled to the mating connector 332 to therebyelectrically couple the coil 200 and the sensor 208 to the wire harness250.

While the bulkhead connector 212 has been described thus far as beingemployed for coupling the coil and sensor of an electronic lockingdifferential to a wire harness, those skilled in the art will appreciatethat the invention, in its broader aspects, may also be employed inconjunction with various other types of power transmitting devicesincluding power take-offs, front differentials, transfer cases andtransmissions, to permit electrical components, such as sensors andactuators, contained therein to be coupled to a wire harness.

Furthermore, although the bulkhead connector 212 has been described thusfar as having a fitting 300 with a single seal 304 that is retained in aseal groove 348 and which seals about the perimeter of the body portion312 and a locking member 308 that is fixedly coupled to the housing 40of the differential assembly 30, those skilled in the art willappreciate that the invention, in its broader aspects, may beconstructed somewhat differently. For example, the bulkhead connector212 may employ a pair of seals 304 and 304 a as shown in FIG. 7. In thisarrangement, the seal 304 a is coupled to the body portion 312 of thefitting 300 and configured to sealing engage the flange 316 and acounterbored surfaces 400 on the interior of the housing 40 a of thedifferential assembly 30 a. As those skilled in the art will appreciate,the seal 304 and corresponding seal groove 348 on the body portion 312of the fitting 300 may optionally be omitted, so that only the seal 304a sealingly engages the housing 40 b and the flange 316 as illustratedin FIG. 8.

In the embodiment of FIGS. 9 and 10, the locking member 308 c isillustrated to have legs 360 c that each have a raised portion 420 thatmay be resiliently deflected relative to the remainder of the legs 360c. When the locking member 308 c is engaged to the retainer groove 340,the raised portions 420 generate a biasing force that is exerted againstthe housing 40 and the body portion 312 of the fitting 300 which tendsto pull the body portion 312 of the fitting 300 through the housing 40.In this embodiment, contact between the flange 316 and the housing 40limits movement of the body portion 312 relative to the housing 40 sothat the biasing force generated by the locking member 308 c operablylocks the fitting 300 to the housing 40.

While the locking member has been described thus far as being slidablyengaged to the body portion of the fitting, those of ordinary skill inthe art will appreciate from this disclosure that the locking member maybe otherwise configured. For example, the locking member may be aconventional external snap ring.

While the invention has been described in the specification andillustrated in the drawings with reference to various embodiments, itwill be understood by those skilled in the art that various changes maybe made and equivalents may be substituted for elements thereof withoutdeparting from the scope of the invention as defined in the claims. Inaddition, many modifications may be made to adapt a particular situationor material to the teachings of the invention without departing from theessential scope thereof. Therefore, it is intended that the inventionnot be limited to the particular embodiments illustrated by the drawingsand described in the specification as the best mode presentlycontemplated for carrying out this invention, but that the inventionwill include any embodiments falling within the foregoing descriptionand the appended claims.

1. A power transmitting device comprising: a housing defining aninternal chamber and a hole communicating with said chamber; a rotaryinput member; a rotary output member; a gearset disposed within saidchamber and operable for transmitting rotary power from said inputmember to said output member; an electrical component disposed in saidchamber; a wiring harness disposed outside of said housing; and aconnector assembly for providing an electrical connection between saidelectrical component and said wiring harness, said connector assemblyincluding a fitting member, a seal member and a locking member, saidfitting member electrically connected to said electrical component andhas a body extending through said hole such that its end portion extendsbeyond an outer wall surface of said housing, said seal member isdisposed between said fitting member and said housing to form a sealedinterface therebetween, and said locking member engages said end portionof said body to secure said fitting member to said housing.
 2. The powertransmitting device of claim 1 wherein said end portion of said bodyincludes electrical terminals adapted for mating with electricalterminals on said wiring harness.
 3. The power transmitting device ofclaim 1 wherein said fitting member further includes a flangesurrounding said body and which is configured to be located in proximityto an inner wall surface of said housing upon insertion of said fittingmember into said hole.
 4. The power transmitting device of claim 3wherein said seal member is disposed between said flange of said fittingmember and said inner wall surface of said housing.
 5. The powertransmitting device of claim 3 wherein said flange is seated in acounterbore formed in said inner wall surface of said housing and whichcommunicates with said hole.
 6. The power transmitting device of claim 1where in said body includes a groove within which said seal member isseated so as to provide said sealed interface between said fittingmember and said housing within said hole.
 7. The power transmittingdevice of claim 6 where in said body includes a second groove formed inits end portion within which said locking member is retained.
 8. Thepower transmitting device of claim 7 wherein said locking member is aU-shaped components having first and second legs operable to engage saidsecond groove for securing said fitting member to said housing.
 9. Thepower transmitting device of claim 8 wherein said locking member furtherincludes a base interconnecting said first and second legs, and whereina fastener secures said base to said outer wall surface of said housing.10. The power transmitting device of claim 7 wherein one of said lockingmember and said second groove include an anti-rotation mechanism forpreventing said locking member from rotating relative to said fittingmember.
 11. The power transmitting device of claim 1 wherein saidgearset is a differential with said rotary output member defining a pairof output shafts, and wherein said electrical component is an electricalactuator operable to releaseably engage said differential.
 12. The powertransmitting device of claim 11 further including a second electricalcomponent defined as an electric sensor for detecting the rotary speedof said differential or one of said output shafts, and wherein saidconnector assembly provides electrical connection between said actuatorand said sensor with said wiring harness.
 13. The power transmittingdevice of claim 1 wherein said gearset is a differential and said rotaryoutput member defines an output shaft driven by said differential, andwherein said electrical component is a sensor operable to detect therotary speed of said differential or said output shaft.
 14. An axleassembly, comprising: an axle housing defining an internal chamber; apinion shaft having a pinion gear; first and second axleshafts; adifferential rotatably supported in said chamber and having a casingdriven by a ring gear meshed with said pinion gear, first and secondside gears driving said first and second axleshafts, and differentialgears for transferring rotary power from said casing to said axleshaftswhile permitting speed differentiation therebetween; a limitingmechanism for selectively limiting relative rotation between said casingand one of said side gears; an electrical actuator operable to actuatesaid limiting mechanism; an electric sensor for detecting the rotaryspeed of one of said casing and said first and second axleshafts; acontrol system for receiving electrical sensor signals from said sensorand supplying electrical control signals to said actuator, said controlsystem including a controller and a wiring harness in electricalconnection with said controller; and a connector assembly for providingan electrical connection between said actuator and said sensor and saidwiring harness, said connector assembly including a fitting member and alocking member, said fitting member is electrically connected to saidactuator and said sensor and has a body extending through a hole in saidaxle housing such that its end portion extends beyond an outer wallsurface of said axle housing, said locking member engages said endportion of said body to secure said fitting member to said axle housing.15. The axle assembly of claim 14 wherein said end portion of said bodyincludes electrical terminals adapted for mating with electricalterminals on said wiring harness.
 16. The axle assembly of claim 14wherein said fitting member further includes a flange surrounding saidbody and which is configured to be located in proximity to an inner wallsurface of said axle housing upon insertion of said fitting member intosaid hole.
 17. The axle assembly of claim 16 wherein a seal is disposedbetween said flange of said fitting member and said inner wall surfaceof said axle housing.
 18. The axle assembly of claim 14 where in saidbody includes a groove within which a seal is seated so as to provide asealed interface between said fitting member and said axle housingwithin said hole.
 19. The axle assembly of claim 18 where in said bodyincludes a second groove formed in its end portion within which saidlocking member is retained.
 20. The axle assembly of claim 19 whereinsaid locking member is a U-shaped components having first and secondlegs operable to engage said second groove for securing said fittingmember to said axle housing.
 21. The axle assembly of claim 20 whereinsaid locking member further includes a base interconnecting said firstand second legs, and wherein a fastener secures said base to said outerwall surface of said axle housing.
 22. The axle assembly of claim 18wherein one of said locking member and said second groove include ananti-rotation mechanism for preventing said locking member from rotatingrelative to said fitting member.
 23. A power transmitting device,comprising: a housing having an internal chamber and a wall defining aninner wall surface and an outer wall surface with a hole therebetween;an input member rotatably supported by said housing; an output memberrotatably supported by said housing; a torque transfer unit disposed insaid chamber for transferring drive torque from said input member tosaid output member; an electrical component disposed in said chamber; awiring harness disposed outside of said housing; and a connectorassembly for providing an electrical connection between said electricalcomponent and said wiring harness, said connector assembly including afitting member, a seal member and a locking member, said fitting memberis electrically connected to said electrical component and has a bodyextending through said hole such that its end portion extends beyondsaid outer wall surface of said housing, said seal member is disposedbetween said fitting member and said housing to form a sealed interfacetherebetween, and said locking member engages said end portion of saidbody to secure said fitting member to said housing.
 24. The powertransmitting device of claim 23 wherein said end portion of said bodyincludes electrical terminals adapted for mating with electricalterminals on said wiring harness.
 25. The power transmitting device ofclaim 23 wherein said fitting member further includes a flangesurrounding said body and which is configured to be located in proximityto said inner wall surface of said housing upon insertion of saidfitting member into said hole.
 26. The power transmitting device ofclaim 25 wherein said seal member is disposed between said flange ofsaid fitting member and said inner wall surface of said housing.
 27. Thepower transmitting device of claim 25 wherein said flange is seated in acounterbore formed in said inner wall surface of said housing and whichcommunicates with said hole.
 28. The power transmitting device of claim23 wherein said body includes a groove within which said seal member isseated.
 29. The power transmitting device of claim 28 where in said bodyincludes a second groove formed in its end portion within which saidlocking member is retained.
 30. The power transmitting device of claim29 wherein said locking member is a U-shaped components having first andsecond legs operable to engage said second groove for securing saidfitting member to said housing.
 31. The power transmitting device ofclaim 30 wherein said locking member further includes a baseinterconnecting said first and second legs, and wherein a fastenersecures said base to said outer wall surface of said housing.
 32. Thepower transmitting device of claim 28 wherein one of said locking memberand said second groove include an anti-rotation mechanism for preventingsaid locking member from rotating relative to said fitting member.